IGF::OT::IGF RESEARCH IS PROPOSED TO DEMONSTRATE THE USE OF ADVANCED MANUFACTURING TECHNIQUES TO ENABLE THE…

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IGF::OT::IGF RESEARCH IS PROPOSED TO DEMONSTRATE THE USE OF ADVANCED MANUFACTURING TECHNIQUES TO ENABLE THE AFFORDABLE APPLICATION OF MULTI-FUNCTIONAL THERMAL / ENVIRONMENTAL BARRIER COATINGS (T/EBCS) HAVING ENHANCED RESISTANCE TO HIGH TEMPERATURE COMBUSTION ENVIRONMENTS. T/EBCS ARE ENVISIONED TO PROTECT THE SURFACE OF SI-BASED CERAMICS AGAINST MOISTURE-ASSISTED, OXIDATION-INDUCED CERAMIC RECESSION. CURRENT T/EBC SYSTEMS HAVE BEEN DEMONSTRATED IN LONG TIME EXPOSURES AT ~2400 F SUBSTRATE TEMPERATURES. HOWEVER, THEIR USE AT ELEVATED TEMPERATURES (I.E. 2700 F SUBSTRATE TEMPERATURES) IS LIMITED BY THE LOW TEMPERATURE STABILITY AND HIGH DIFFUSION ACTIVITY OF CURRENT T/EBC MATERIALS. ONE APPROACH TO INCREASE THE TEMPERATURE CAPABILITY OF THESE SYSTEMS IS THE INCORPORATION OF MULTI-LAYERED T/EBC DESIGNS. IN THIS PHASE I EFFORT, ENHANCED PROCESSING TECHNIQUES WILL BE EMPLOYED TO DEMONSTRATE THE MANUFACTURE OF ROBUST T/EBC BOND COAT SYSTEMS USING A PHYSICAL VAPOR DEPOSITION BASED PROCESSING APPROACH WHICH ENABLES IMPROVED COATING ADHESION AND ADVANCED COATING ARCHITECTURAL, COMPOSITIONAL AND MICROSTRUCTURAL CONTROL, AS WELL AS NON-LINE-OF-SIGHT (NLOS) DEPOSITION. SCALED PROCESSING APPROACHES WILL THEN BE USED TO DEMONSTRATE THE DEPOSITION OF HIGH TEMPERATURE CAPABLE T/EBC BOND COATS ONTO COMPONENTS OF INTEREST TO GAS TURBINE ENGINE MANUFACTURERS. THESE BOND COATS WILL THEN BE INCORPORATED INTO FULL HIGH TEMPERATURE CAPABLE T/EBC SYSTEMS PLANNED IN PHASE II. FINALLY, CONCEPTS TO ENABLE THE DEPOSITION OF T/EBC BOND COAT SYSTEMS ON NLOS INTERNAL REGIONS OF HOLLOW COMPONENTS WILL BE INVESTIGATED. THIS WORK WILL SIGNIFICANTLY AID THE INCORPORATION OF SI-BASED CERAMIC COMPONENTS IN GAS TURBINE ENGINES RESULTING IN REDUCED WEIGHT AND INCREASED OPERATING TEMPERATURES.